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KOMATSU 930E-4 DUMP TRUCK OPERATION & MAINTENANCE MANUAL (SN:A30462 – A30600) KOMATSU 930E-4 – PDF DOWNLOAD
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- KOMATSU 930E-4 DUMP TRUCK OPERATION & MAINTENANCE MANUAL
- SERIAL NUMBER:A30462 – A30600
- PUBLICATION NUMBER:CEAM017906
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KOMATSU 930E-4 DUMP TRUCK OPERATION & MAINTENANCE MANUAL (SN:A30462 – A30600) KOMATSU 930E-4
KOMATSU 930E-4 DUMP TRUCK OPERATION & MAINTENANCE MANUAL (SN:A30462 – A30600) KOMATSU 930E-4 – PDF DOWNLOAD:
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KOMATSU 930E-4 DUMP TRUCK OPERATION & MAINTENANCE MANUAL (SN:A30462 – A30600) KOMATSU 930E-4
- This manual is written for use by the omrator and/or the service technician. It is designed to help these persons to become fully knowledgeable of the truck and all of its systems in orderto keep it omrating safely and efficiently. All operators and maintenance personnel should read and understand the information in this manual before operating the truck or performing maintenance andlor owrational checks on the truck. All safety notices, wamings, and cautions should m understood and followed when operating the truck or performing repairs on the truck
- A product identification plate is located on the frame in front of the right side front wheel. It designates the Truck Model Number, Product Identification Number (vehicle serial number), and Maximum GVW (Gross Vehicle Weight) rating.
- The KOMATSU truck model designation consists of three numbers and one letter
- The three numbers represent the basic truck model.
- The letter ‘M’, when present, designates a Mechanical drive system.
- The letter ‘E’, when present, designates an Electrical wheel motor drive system.
- The Product Identification NumMr (vehicle serial number) contains information which identifies the original manufacturing bill of material for this unit This complete number will be necessary for proper ordering of many service parts and/or warranty consideration.
- The Gross Vehicle Weight (GVW) is what determines the load on the drive train, frame, tires, and other components. The vehicle design and application guidelines are sensitive to the maximum GVW. GVW is total weight empty vehicle weight + fuel 8. lubricants + payload.
TABLE OF CONTENTS:
KOMATSU 930E-4 DUMP TRUCK OPERATION & MAINTENANCE MANUAL (SN:A30462 – A30600) KOMATSU 930E-4
COVER........................................................................... 1 INTRODUCTION.................................................................... 5 FOREWORD.................................................................... 5 TRUCK MODEL ILLUSTRATION.................................................... 6 ABOUT THIS MANUAL........................................................... 7 ALERTS PAGE................................................................. 8 TABLE OF CONTENTS............................................................... 9 TORQUE TABLES AND CONVERSION CHARTS............................................. 19 EFFECT OF SPECIAL LUBRICANTS On Fasteners and Standard Torque Values........ 20 STANDARD TIGHTENING TORQUES For Class 10.9 Cap screws & Class 10 Nuts....... 20 STANDARD TIGHTENING TORQUES For SAE Grade 5 and Grade 8 Cap screws.......... 21 STANDARD TIGHTENING TORQUES For SAE Grade 9 Cap screws...................... 22 SAFETY.......................................................................... 29 GENERAL..................................................................... 29 Safety Rules............................................................ 29 Safety Features......................................................... 29 Fire Extinguisher And First Aid Kit..................................... 29 Clothing And Personal Items............................................. 29 Leaving The Operator’s Seat............................................. 30 Mounting And Dismounting................................................ 30 Fire Prevention For Fuel And Oil........................................ 30 Precautions With High Temperature Fluids................................ 31 Asbestos Dust Hazard Prevention......................................... 31 Prevention Of Injury By Work Equipment.................................. 31 Unauthorized Modification............................................... 31 ROPS Precautions........................................................ 31 Precautions For Attachments............................................. 32 Precautions For Starting The Truck...................................... 32 PRECAUTIONS BEFORE OPERATION................................................ 32 Safety At The Worksite.................................................. 32 Fire Prevention......................................................... 33 Ventilation In Enclosed Areas........................................... 33 Preparing For Operation................................................. 33 Mirrors, Windows And Lights............................................. 33 In The Operator Cab (Before Starting The Engine)........................ 33 Seat Belts.............................................................. 33 OPERATING THE TRUCK......................................................... 34 When Starting The Engine................................................ 34 General Truck Operation................................................. 34 Ensuring Good Visibility................................................ 34 Traveling............................................................... 35 Traveling In Reverse.................................................... 35 Traveling On Slopes..................................................... 35 Operating On Snow Or Ice................................................ 35 Avoid Damage To The Dump Body........................................... 35 Driving Near High Voltage Cables........................................ 36 Working On Loose Ground................................................. 36 When Dumping............................................................ 36 When Loading............................................................ 36 Parking The Truck....................................................... 36 Towing.................................................................. 36 WORKING NEAR BATTERIES...................................................... 37 Battery Hazard Prevention............................................... 37 Starting With Booster Cables............................................ 37 BEFORE PERFORMING MAINTENANCE............................................... 38 Stopping The Engine..................................................... 38 Warning Tag............................................................. 38 Proper Tools............................................................ 38 Securing The Dump Body.................................................. 38 WHILE PERFORMING MAINTENANCE................................................ 39 Keep The Truck Clean.................................................... 39 Attachments............................................................. 39 Working Under The Truck................................................. 39 Rotating Fan And Belts.................................................. 39 Waste Materials......................................................... 39 Adding Fuel Or Oil...................................................... 40 Radiator Coolant Level.................................................. 40 Use Of Lighting......................................................... 40 Precautions With The Battery............................................ 40 Handling High Pressure Hoses............................................ 40 Precautions With High Pressure Oil...................................... 40 Performing Maintenance Near High Temperature Or High Pressure........... 40 TIRES....................................................................... 41 Handling Tires.......................................................... 41 Storing Tires After Removal............................................. 41 WHEN REPAIRS ARE NECESSARY.................................................. 42 SPECIAL PRECAUTIONS FOR WORKING ON AC DRIVE TRUCKS.......................... 43 PRELIMINARY PROCEDURES BEFORE WELDING OR PERFORMING MAINTENANCE......... 43 ENGINE SHUTDOWN PROCEDURE BEFORE WELDING OR PERFORMING MAINTENANCE...... 43 CAPACITOR DISCHARGE SYSTEM.............................................. 45 Necessary Tools..................................................... 45 Warnings And Cautions............................................... 46 Manual DC Link Capacitor Discharge Procedure........................ 47 Failure of the Discharge System..................................... 49 Manual Discharge of Capacitors...................................... 50 Short Isolated Capacitor Terminals.................................. 52 ADDITIONAL JOB SITE RULES............................................... 54 WARNINGS AND CAUTIONS........................................................... 55 GRADE/SPEED CHART........................................................... 55 KEY SWITCH.................................................................. 55 ROPS/FOPS................................................................... 55 BATTERIES................................................................... 56 CAPACITORS.................................................................. 56 CRUSHING HAZARD............................................................. 57 CYLINDER PRESSURE........................................................... 57 FILLING THE HYDRAULIC TANK.................................................. 58 HYDRAULIC OIL PRESSURE...................................................... 58 HOT OIL SPRAY............................................................... 59 WHEEL MOTOR OIL LEVEL....................................................... 59 HOT EXHAUST................................................................. 59 RADIATOR.................................................................... 59 EMERGENCY LADDER............................................................ 59 ACCUMULATOR DRAIN VALVES.................................................... 59 EMERGENCY DUMP PROCEDURE.................................................... 60 EMERGENCY TOWING PROCEDURE.................................................. 60 WELDING..................................................................... 60 EMERGENCY SHUTDOWN.......................................................... 60 INFORMATION DISPLAY......................................................... 61 WIRELESS SIGNALS............................................................ 61 HIGH VOLTAGE................................................................ 61 LIFTING INSTRUCTIONS........................................................ 62 PRODUCT IDENTIFICATION PLATE................................................ 63 LUBRICATION CHART........................................................... 64 OPERATING INSTRUCTIONS.......................................................... 65 PREPARING FOR OPERATION..................................................... 65 WALK AROUND INSPECTION...................................................... 65 ENGINE START-UP............................................................. 69 AFTER ENGINE START-UP....................................................... 70 EMERGENCY STEERING SYSTEM................................................... 70 Operation............................................................... 70 Pre-Operation Testing................................................... 70 MACHINE OPERATION SAFETY PRECAUTIONS........................................ 71 OPERATING ON THE HAUL ROAD.................................................. 72 STARTING ON A GRADE WITH A LOADED TRUCK..................................... 73 PASSING..................................................................... 73 LOADING..................................................................... 73 Overload Speed Limit Function........................................... 73 DUMPING..................................................................... 74 Raising The Dump Body................................................... 74 Lowering The Dump Body (When dumping on flat ground):................... 75 Lowering The Dump Body (When dumping over a berm or into a crusher):.... 75 TOWING...................................................................... 76 SAFE PARKING PROCEDURES..................................................... 76 NORMAL ENGINE SHUTDOWN PROCEDURE............................................ 77 SUDDEN LOSS OF ENGINE POWER................................................. 77 FUEL DEPLETION.............................................................. 78 DISABLED TRUCK DUMPING PROCEDURE............................................ 78 Hookup.................................................................. 78 Raising the Body........................................................ 79 Lowering the Body....................................................... 79 RESERVE ENGINE OIL SYSTEM................................................... 80 Operation............................................................... 80 Changing Oil............................................................ 80 OPERATOR CAB AND CONTROLS....................................................... 81 STEERING WHEEL AND CONTROLS................................................. 82 Horn Button............................................................. 82 Tilt / Telescope Lever.................................................. 82 Multi-Function Turn Signal Switch....................................... 82 DYNAMIC RETARDING........................................................... 83 Retarder Lever.......................................................... 83 Brake/Retarder Pedal.................................................... 83 Throttle/Accelerator Pedal.............................................. 83 GRADE/SPEED CHART........................................................... 84 OVERHEAD PANEL AND DISPLAYS................................................. 85 CENTER CONSOLE.............................................................. 86 Directional Control Lever............................................... 86 Override/Fault Reset Switch............................................. 87 Engine Shutdown Switch.................................................. 87 Window Control Switches................................................. 87 Hoist Control Lever..................................................... 87 Retard Speed Control (RSC) Adjustment Dial.............................. 88 Retard Speed Control (RSC) Switch....................................... 88 Data Store Button....................................................... 89 KOMTRAX Plus Snapshot In Progress Light................................. 89 Link Energized Light.................................................... 89 Service Engine Light.................................................... 89 12V Auxiliary Power Outlets............................................. 89 DIAGNOSTIC PORTS............................................................ 89 KOMTRAX Plus Diagnostic Port............................................ 89 Interface Module (IM) Diagnostic Port................................... 89 Payload Meter Diagnostic Port........................................... 89 Truck Control Interface (TCI) Diagnostic Port........................... 89 Propulsion System Controller (PSC) Diagnostic Port...................... 89 Engine Diagnostic Port (CENSE).......................................... 89 Engine Diagnostic Port (QUANTUM)........................................ 89 OPERATOR’S SEAT............................................................. 90 Seat Belts.............................................................. 90 Adjustment.............................................................. 90 HEATER/AIR CONDITIONER COMPARTMENT AND CONTROLS............................. 91 Fan Speed Control Knob.................................................. 91 Temperature Control Knob................................................ 91 Air Flow Directional Knob............................................... 91 Heater/Air Conditioner Vents............................................ 91 INSTRUMENT PANEL............................................................ 92 Control Symbols......................................................... 92 Key Switch.............................................................. 94 Engine Shutdown Timer Switch - 5 Minute Idle Delay...................... 94 Air Conditioner Compressor Switch....................................... 94 Rotating Beacon Switch (optional)....................................... 94 Heated Mirrors Switch (optional)........................................ 94 AC Drive System Rest Switch............................................. 95 Wheel Brake Lock Switch................................................. 95 Hazard Warning Light Switch............................................. 95 Heater/Air Conditioner Vents............................................ 95 Engine Oil Pressure Gauge............................................... 96 Right Turn Signal Indicator............................................. 96 Digital Tachometer...................................................... 96 High Beam Indicator..................................................... 96 Speedometer/Payload Meter Display....................................... 96 Left Turn Signal Indicator.............................................. 96 Coolant Temperature Gauge............................................... 96 Lamp Check Switch....................................................... 96 Light Switch (3-Way).................................................... 96 Ladder Light Switch..................................................... 97 Backup Light Switch..................................................... 97 Fog Light Switch........................................................ 97 Payload Meter Switch.................................................... 97 Panel Illumination Light Dimmer Switch.................................. 97 Hydraulic Oil Temperature Gauge......................................... 97 Engine Hourmeter........................................................ 97 Fuel Gauge.............................................................. 97 OVERHEAD STATUS / WARNING INDICATORS........................................ 98 A1. High Brake Oil Temperature.......................................... 99 B1. Low Steering Pressure............................................... 99 C1. Low Accumulator Precharge Pressure..................................100 D1. Not used............................................................100 E1. Low Brake Pressure..................................................100 A2. Low Hydraulic Tank Level............................................100 B2. Low Automatic Lubrication System Pressure...........................100 C2. Circuit Breaker Tripped.............................................100 D2. Hydraulic Oil Filter Monitor........................................100 E2. Low Fuel............................................................101 A3. Parking Brake.......................................................101 B3. Service Brake.......................................................101 C3. Body Up.............................................................101 D3. Dynamic Retarding...................................................101 E3. Stop Engine.........................................................101 A4. Cranking Motor Failure..............................................101 B4. Backup Lights.......................................................101 C4. Engine Shutdown Timer - 5 Minute Idle...............................102 D4. Retard Speed Control (RSC) Indicator................................102 E4. Check Engine........................................................102 A5. No Power............................................................102 B5. Propulsion System Warning...........................................102 C5. Propulsion System Temperature.......................................102 D5. System/Component Failure............................................102 E5. Battery Charging System Failure.....................................102 A6. No Propel...........................................................103 B6. Propel System At Rest...............................................103 C6. Propel System Not Ready.............................................103 D6. Reduced Propulsion..................................................103 E6. Retard At Continuous Level..........................................103 REAR AXLE LIGHT BAR.........................................................104 Backup Lights...........................................................104 Retard Lights...........................................................104 Brake Light.............................................................104 Backup Alarm............................................................104 KOMTRAX PLUS................................................................105 Operation...............................................................105 Interface Module........................................................107 Basic Precautions.......................................................107 KOMATSU WIRELESS BRIDGE (Optional)..........................................108 General Information.....................................................108 Communication Setup.....................................................108 Switching to the KWB_SETUP Network......................................108 Setting the Computer Subnet Mask and IP Address.........................109 Properties..............................................................109 Setting Up the KWB......................................................110 Adding Encryption.......................................................110 Final Computer Settings.................................................110 Data Downloading........................................................111 Resetting the KWB.......................................................111 KWB Lights..............................................................111 FUSES AND CIRCUIT BREAKERS..................................................112 LUBRICATION AND SERVICE.........................................................115 GENERAL.....................................................................115 SERVICE CAPACITIES..........................................................115 HYDRAULIC TANK SERVICE......................................................115 Adding Oil..............................................................115 COOLING SYSTEM SERVICE......................................................116 Radiator Filling Procedure..............................................116 Coolant Specifications..................................................116 Unacceptable Practices..................................................116 WHEEL MOTOR SERVICE.........................................................116 RESERVE OIL TANK SERVICE....................................................117 Filling the Reserve Oil Tank (Remote Fill)..............................117 Inline Screen...........................................................117 QUICK FILL SERVICE CENTER...................................................118 LUBRICATION CHART...........................................................119 10 HOUR (DAILY) INSPECTIONS.................................................120 50 HOUR LUBRICATION AND MAINTENANCE CHECKS..................................122 100 HOUR LUBRICATION AND MAINTENANCE CHECKS.................................122 250 HOUR LUBRICATION AND MAINTENANCE CHECKS.................................122 500 HOUR LUBRICATION AND MAINTENANCE CHECKS.................................125 1000 HOUR LUBRICATION AND MAINTENANCE CHECKS................................127 5000 HOUR MAINTENANCE CHECKS................................................127 AUTOMATIC LUBRICATION SYSTEM....................................................129 GENERAL DESCRIPTION.........................................................129 SYSTEM COMPONENTS...........................................................131 Filter..................................................................131 Hydraulic Motor and Pump................................................131 Grease Reservoir........................................................131 Pressure Reducing Valve.................................................131 Flow Control Valve......................................................131 Solenoid Valve..........................................................131 Vent Valve..............................................................131 Lubrication Cycle Timer.................................................131 Over Pressure Cut Off Switch............................................131 Grease Pressure Failure Switch..........................................131 Injectors...............................................................131 Relief Valve (unloader valve)...........................................131 SYSTEM OPERATION............................................................132 Normal Operation........................................................132 GENERAL INSTRUCTIONS........................................................133 Lubricant Required For System...........................................133 System Priming..........................................................133 Filter Assembly.........................................................133 LUBRICANT PUMP..............................................................134 Pump Housing Oil Level..................................................134 Pump Pressure Control...................................................134 INJECTORS (SL-1 Series “H”).................................................135 Injector Specifications.................................................135 Injector Adjustment.....................................................135 Injector Operation......................................................136 PREVENTIVE MAINTENANCE PROCEDURES...........................................137 Daily Lubrication System Inspection.....................................137 250 Hour Inspection.....................................................137 1000 Hour Inspection....................................................137 SYSTEM CHECKOUT.............................................................138 Lubrication Controller Check............................................138 Lubrication Controller Components.......................................138 Lubrication Controller Adjustment.......................................138 SYSTEM TROUBLESHOOTING CHART................................................140 COMPONENTS & SPECIFICATIONS.....................................................143 MAJOR COMPONENT DESCRIPTIONS................................................143 Truck And Engine........................................................143 Main Alternator.........................................................143 AC Induction Traction Motorized Wheels..................................143 Suspension..............................................................143 Operator's Cab..........................................................143 Power Steering..........................................................143 Dynamic Retarding.......................................................143 Brake System............................................................143 SPECIFICATIONS..............................................................145 ENGINE..................................................................145 AC ELECTRIC DRIVE SYSTEM................................................145 DYNAMIC RETARDING.......................................................145 BATTERY ELECTRIC SYSTEM.................................................145 SERVICE CAPACITIES......................................................145 HYDRAULIC SYSTEMS.......................................................146 SERVICE BRAKES..........................................................146 STEERING................................................................146 TIRES...................................................................146 STANDARD DUMP BODY CAPACITIES AND DIMENSIONS............................146 WEIGHT DISTRIBUTION.....................................................147 PAYLOAD METER III...............................................................149 RADIO / CASSETTE PLAYER.........................................................179 GENERAL RECEIVER FUNCTIONS..................................................179 Turning The Power On And Off............................................179 Display.................................................................179 Setting The Default Display.............................................179 Adjusting Display Brightness............................................179 SETTING THE TIME............................................................180 OPERATING THE RADIO.........................................................180 BAND....................................................................180 TUNE/SEEK...............................................................180 Manual Tuning...........................................................180 SEEK Mode...............................................................180 SCAN....................................................................180 AUTO....................................................................180 ADJUSTING THE RECEIVER SETTINGS.............................................181 PROGRAMMING PRESET STATIONS.................................................181 OPERATION OF THE WEATHERBAND (U.S.).........................................181 SATELLITE RADIO.............................................................182 Operating Satellite Radio...............................................182 Program Type Search (PTY)...............................................182 CASSETTE PLAYER.............................................................183 Playing A Cassette......................................................183 Cassette Functions......................................................183 Programmable Eject Default..............................................183 Bad Tape Detect.........................................................184 Cleaning The Cassette Player............................................184 AM/FM RADIO / CD PLAYER.........................................................185 GENERAL RADIO RECEIVER FUNCTIONS............................................185 Turning On the Power....................................................185 One-Hour Timer..........................................................185 Display.................................................................186 Setting a Default Display...............................................186 Adjusting the Brightness of the Display.................................186 Auxiliary Mode..........................................................186 Adjusting the Receiver Settings.........................................186 USING THE CLOCK.............................................................187 Setting the Clock.......................................................187 USING THE ALARM.............................................................187 Setting the Alarm.......................................................187 Turning the Alarm Off...................................................187 Activating Snooze.......................................................187 Setting Alarm Volume....................................................187 USING THE RADIO.............................................................188 Finding a Station.......................................................188 Setting the Presets.....................................................188 USING THE WEATHERBAND.......................................................189 USING THE COMPACT DISC PLAYER...............................................189 Playing a Compact Disc..................................................189 Button Functions........................................................189 PLAYING AN MP3 DISC.........................................................190 MP3 Format Compatibility................................................190 Root Directory..........................................................190 Empty Directory or Folder...............................................190 No Folder...............................................................190 File Name Display.......................................................190 Pre-Programmed Playlists................................................191 Playing MP3 Files.......................................................191 Button Functions........................................................191 TROUBLESHOOTING.............................................................192
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